Bi-fold door module

ABSTRACT

A door module for a vehicle lavatory that includes a bi-fold door having a first panel and a second panel each having an inner surface and an outer surface. The first and second panels are pivotably connected together by a living hinge. The living hinge includes a hinge member that extends between first and second securing members, wherein the first securing member extends along and is attached to an inner edge of the first panel and the second securing member extends along and is attached to an inner edge of the second panel.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent applicationSer. No. 14/670,016, filed Mar. 26, 2015, which claims the benefit ofU.S. Provisional Application No. 62/054,299, filed Sep. 23, 2014 andU.S. Provisional Application No. 61/971,495, filed Mar. 27, 2014, whichare all incorporated by reference herein in their entireties.

FIELD OF THE INVENTION

The present invention relates generally to a door module, and moreparticularly to a door module for use with a lavatory module in anaircraft.

BACKGROUND OF THE INVENTION

Commercial aircraft, such as the Airbus A320 or Boeing 737, aretypically constructed from modular components, the size, weight andconstruction of which are dictated by many considerations, includingfuselage dimensions, aesthetic and safety. Many of these requirementsare imposed by law or regulation. Aircraft components, such as overheadstowage compartments, seats, lavatories, galleys, lighting systems, etc.are all required to function within strictly confined spaces.

Manufacturers of aircraft are constantly refining interior aircraftdesigns to achieve more comfort and utility for passengers and crewwithin carrier-imposed restraints on cost, weight, maintenancedown-time, and safety. Commercial passenger aircraft generally includelavatories for use by passengers and crew that include a door on one ofthe walls thereof. Opening a bi-fold door can often be tricky. Thepresent invention helps make the opening of a bi-fold door moreintuitive and obvious. This is achieved by providing a large paddlehandle that, due to its shape, is effective at communicating to a userthe function of the door as it is intuitive where to place one's handand to pull instead of push. This, together with other advantages of thedoor module, is discussed below.

SUMMARY OF THE PREFERRED EMBODIMENTS

In accordance with a first aspect of the present invention there isprovided a door module for a vehicle lavatory that includes a bi-folddoor having a first panel and a second panel each having an innersurface and an outer surface. The first and second panels are pivotablyconnected together by a living hinge. The living hinge includes a hingemember that extends between first and second securing members, whereinthe first securing member extends along and is attached to an inner edgeof the first panel and the second securing member extends along and isattached to an inner edge of the second panel. In a preferredembodiment, the hinge member includes opposite edges, the first andsecond securing members each include an elongated groove definedtherein, and the elongated grooves capture the opposite edges of thehinge member. Preferably, the door module also includes a latchingassembly positioned in the first panel. The latching assembly operatesan elongated locking bolt, the first securing member includes a firsttunnel defined therein, and the locking bolt extends through and abovethe first tunnel. Preferably, the first securing member includes a latchopening defined therein that is communication with the first tunnel, anda portion of the latching assembly extends through the latch opening andinto the first tunnel.

In a preferred embodiment, the bi-fold door is positioned in a dooropening that is defined in a wall and is movable between a closedposition and an open position. The outer edge of the first panelincludes a first nesting member thereon, an inner edge of the walladjacent the outer edge of the first panel includes a second nestingmember thereon, and at least a portion of the first and second nestingmembers overlap in a transverse direction when the bi-fold door is inthe closed position. Preferably, the first nesting member includes anon-engagement portion and an engagement portion, the second nestingmember includes a non-engagement portion and an engagement portion, andwhen a force is placed on the inner surface of the first panel, theengagement portion of the first nesting member contacts the engagementportion of the second nesting member to prevent the bi-fold door fromopening. Preferably, the non-engagement portion of the first nestingmember is generally parallel to the outer edge of the first panel, andthe non-engagement portion of the second nesting member is generallyparallel to the inner edge of the wall.

In a preferred embodiment, an outer paddle handle is secured to andextends outwardly from the first panel such that it overlaps at least aportion of the wall and an inner paddle handle is secured to the secondpanel and overlaps at least a portion of the first panel (and/or theliving/central hinge). Preferably, the wall includes a handleindentation defined therein, and the outer paddle handle overlaps andcooperates with the handle indentation to define an opening space.Preferably, an insert is positioned in the handle indentation, and theinsert includes a ramp portion leading into and partially defining theopening space. In a preferred embodiment, the outer edge of the secondpanel includes an edge cap secured thereto that includes a tunnelextending therethrough. An upper hinge member is positioned in thetunnel such that an upper hinge pin extends above the edge cap, and alower hinge member is positioned in the tunnel such that a lower hingepin extends below the edge cap.

In accordance with another aspect of the present invention there isprovided a door module for a vehicle lavatory that includes a wall thatincludes a door opening defined therein, and a bi-fold door positionedin the door opening and movable between a closed position and an openposition. The bi-fold door includes a first panel and a second paneleach having an inner surface and an outer surface and that are pivotablyconnected together by a living hinge. The living hinge includes a hingemember that extends between first and second securing members. The firstsecuring member extends along and is attached to an inner edge of thefirst panel and the second securing member extends along and is attachedto an inner edge of the second panel. The hinge member includes oppositeedges, the first and second securing members each include an elongatedgroove defined therein, and the elongated grooves capture the oppositeedges of the hinge member. The outer edge of the first panel includes afirst nesting member thereon, an inner edge of the wall adjacent theouter edge of the first panel includes a second nesting member thereon,and at least a portion of the first and second nesting members overlapin a transverse or lateral direction when the bi-fold door is in theclosed position. An outer paddle handle is secured to and extendsoutwardly from the first panel such that it overlaps at least a portionof the wall, and an inner paddle handle is secured to the second paneland overlaps at least a portion of the first panel.

In a preferred embodiment, the door includes a living hinge as thecentral hinge. Preferably, the living hinge includes cold extrudedplastic and rubber. In a preferred embodiment, the leading edge of thedoor and door jamb are interlocking or complementary. Preferably, thedoor jamb includes a groove or curved surface that the leading edge ofthe door fits into. In use, when the door closes, the leading edge ismoving toward the jamb (translating), but is also turning. This motionis captured by the interlocking of the door and the door jamb, asdescribed herein. Preferably, the interlocking surfaces are part ofextrusions that are secured to the door and the door jamb. Thisinterlocking provides security to someone using the lavatory and helpsprevent the door from being pushed open when the lavatory is being used.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an outer perspective view of a door module and wall panel inaccordance with a preferred embodiment of the present invention;

FIG. 2 is an exploded perspective view of the door module of FIG. 1;

FIG. 3 is a perspective view of the top portion of the door module ofFIG. 1;

FIG. 4 is a cross-sectional perspective view of the top portion of thedoor module of FIG. 1;

FIG. 5 is a cross-sectional plan view of the door module that shows thedoor moving between the open position and the closed position;

FIG. 5A is a detailed view of the interlocking feature of FIG. 5;

FIG. 5B is a detailed view of the living hinge of FIG. 5;

FIG. 6 is a cross-sectional plan view of the outer handle;

FIG. 7 is a perspective view of the upper hinge assembly of the doormodule of FIG. 1;

FIG. 8 is an exploded perspective view of the upper hinge assembly ofthe door module of FIG. 1;

FIG. 9 is an inner perspective view of the door module of FIG. 1;

FIG. 10 is an outer perspective view of a door module and wall panel inaccordance with a second preferred embodiment of the present invention;

FIG. 11 is an exploded perspective view of the door module of FIG. 10;

FIG. 12 is a perspective view of the top portion of the door module ofFIG. 10;

FIG. 13 is a cross-sectional perspective view of the top portion of thedoor module of FIG. 10;

FIG. 14 is a cross-sectional plan view of the door module that shows thedoor moving between the open position and the closed position;

FIG. 14A is a detailed view of the interlocking feature of FIG. 14;

FIG. 14B is a detailed view of the living hinge of FIG. 14;

FIG. 15 is a cross-sectional plan view of the outer handle;

FIG. 16 is a perspective view of the upper hinge assembly of the doormodule of FIG. 10;

FIG. 17 is an exploded perspective view of the upper hinge assembly ofthe door module of FIG. 10; and

FIG. 18 is an inner perspective view of the door module of FIG. 10.

Like numerals refer to like parts throughout the several views of thedrawings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following description and drawings are illustrative and are not tobe construed as limiting. Numerous specific details are described toprovide a thorough understanding of the disclosure. However, in certaininstances, well-known or conventional details are not described in orderto avoid obscuring the description. References to one or an embodimentin the present disclosure can be, but not necessarily are references tothe same embodiment; and, such references mean at least one of theembodiments.

Reference in this specification to “one embodiment” or “an embodiment”means that a particular feature, structure, or characteristic describedin connection with the embodiment is included in at least one embodimentof the disclosure. The appearances of the phrase “in one embodiment” invarious places in the specification are not necessarily all referring tothe same embodiment, nor are separate or alternative embodimentsmutually exclusive of other embodiments. Moreover, various features aredescribed which may be exhibited by some embodiments and not by others.Similarly, various requirements are described which may be requirementsfor some embodiments but not other embodiments.

The terms used in this specification generally have their ordinarymeanings in the art, within the context of the disclosure, and in thespecific context where each term is used. Certain terms that are used todescribe the disclosure are discussed below, or elsewhere in thespecification, to provide additional guidance to the practitionerregarding the description of the disclosure. For convenience, certainterms may be highlighted, for example using italics and/or quotationmarks: The use of highlighting has no influence on the scope and meaningof a term; the scope and meaning of a term is the same, in the samecontext, whether or not it is highlighted.

It will be appreciated that the same thing can be said in more than oneway. Consequently, alternative language and synonyms may be used for anyone or more of the terms discussed herein. No special significance is tobe placed upon whether or not a term is elaborated or discussed herein.Synonyms for certain terms are provided. A recital of one or moresynonyms does not exclude the use of other synonyms. The use of examplesanywhere in this specification including examples of any terms discussedherein is illustrative only, and is not intended to further limit thescope and meaning of the disclosure or of any exemplified term.Likewise, the disclosure is not limited to various embodiments given inthis specification.

Without intent to further limit the scope of the disclosure, examples ofinstruments, apparatus, methods and their related results according tothe embodiments of the present disclosure are given below. Note thattitles or subtitles may be used in the examples for convenience of areader, which in no way should limit the scope of the disclosure. Unlessotherwise defined, all technical and scientific terms used herein havethe same meaning as commonly understood by one of ordinary skill in theart to which this disclosure pertains. In the case of conflict, thepresent document, including definitions, will control.

It will be appreciated that terms such as “front,” “back,” “top,”“bottom,” “side,” “short,” “long,” “up,” “down,” “aft,” “forward,”“inboard,” “outboard” and “below” used herein are merely for ease ofdescription and refer to the orientation of the components as shown inthe figures. It should be understood that any orientation of thecomponents described herein is within the scope of the presentinvention.

FIGS. 1-9 show a door module 10 positioned within a door opening 12 in awall 14. In a preferred embodiment, the door module 10 is used in anaircraft lavatory. However, this is not a limitation on the presentinvention and the door module 10 can be used in other locations. Asshown in the drawings, in a preferred embodiment, the door module 10generally includes a bi-fold door 15 that includes a first panel 16 anda second panel 18 that are secured together and pivotable with respectto one another via a central hinge 20. Preferably, the central hinge 20is a living hinge (described below). However, this is not a limitationon the present invention and the center hinge can also be any other typeof known hinge. The door module 10 also includes a latching assembly 22,an inner handle 24, an outer handle 26, upper and lower hinge members 28and 30, a doorframe edge cap 32, header assembly 34, lower closeout 36,and upper and lower trim 38 and 40. The door module 10 can include othercomponents known in the art such as vents 100, kick plates 102, anashtray 104, door damper 106, etc.

As shown in FIGS. 2-3, in a preferred embodiment, the upper portion ofthe bi-fold door 15 includes a track guide 60 extending upwardly fromthe first panel 16 and the upper trim 38. The track guide 60 moves orslides within a track in the header assembly 34 that is secured to thelower edge of the door opening 12 in the wall 14. The track guide 60 ispositioned such that when the bi-fold door 15 moves between the open andclosed positions, the leading edge of the door moves in a path shown inFIG. 5 and discussed further below. In a preferred embodiment, the upperportion of the bi-fold door 15 also includes a flange 62 having a magnetstrip 64 thereon that interacts with a magnet strip on the headerassembly 34. This helps finish the closing of the door when it is movedto the closed position.

As shown in FIGS. 4-5A, in a preferred embodiment, the leading edge ofthe bi-fold door 15 interlocks or nests within the door jamb when thebi-fold door 15 is in the closed position. To accomplish this, the firstpanel 16 includes a first nesting member 42 secured thereon thatinterlocks with a second nesting member 44 that is secured to the wall14. The first and second nesting members 42 and 44 can extend the entireheight of the door 15 or, as shown in the drawings, there can be upperand lower portions that extend above and below the outer handle 26. Thefirst and second nesting members 42 and 44 each include a channel 46into which the first panel 16 or wall 14 are received. In a preferredembodiment, the first and second nesting members 42 and 44 areextrusions and are secured to (via adhesive, screws, fasteners, etc.) tothe first panel 16 and wall 14. In another embodiment, the first nestingmember can be integral with the first panel and the second nestingmember can be integral with the wall.

It will be appreciated by those of ordinary skill in the art that theinterlocking feature of the first and second nesting members helpsprevent the door from being opened when the door (and, in particular,the first panel) is pushed from the inside (see arrow A1) in FIG. 5A. Ina preferred embodiment, the first nesting member 42 includes anon-engagement portion or surface 42 a and an engagement portion orsurface 42 b. The non-engagement portion 42 a is generally parallel tothe outer edge of the first panel 16 (or generally perpendicular to thefront and back surfaces of the door). The engagement portion 42 b curvesor angles away from the non-engagement portion. The second nestingmember 44 also includes a non-engagement portion 44 a and an engagementportion 44 b. The non-engagement portion 44 a is generally parallel tothe inner edge of the wall 14 (or generally perpendicular to the frontand back surfaces of the wall), and is generally parallel to thenon-engagement portion 42 a of the first nesting member 42. Thenon-engagement portions can also be described as ramp portions. When aforce is placed on the door 15 in the direction of arrow A1, the firstpanel 16 moves outwardly and engagement portion 42 b contacts engagementportion 44 b, thereby preventing the door from opening. Generally, theoverlap between the first and second nesting members 42 and 44 in thelateral and/or transverse directions of the door 15 provides theinterlocking capability. In other words, the profile of the leading edgeof the door and the mating part on the wall or structure are shaped in afashion that they will securely retain the door from any inboardoutboard movement. They also eliminate any direct line of site throughthe gaps, preventing any unwanted light bleed and privacy issues.

It will be appreciated that the path traveled by the leading edge of thedoor, as a result of the interaction between track guide 60 and itstrack is what allows the first and second nesting members 42 and 44 tonest. This path is shown in FIG. 5 with reference to the variouspositions of the door shown in hidden lines and the path the track guide60 must travel within the track.

As shown in FIGS. 4 and 5B, in a preferred embodiment, the central hinge20 is or includes a living hinge that connects the first and secondpanels 16 and 18. In a preferred embodiment, the living hinge includes ahinge member 52 that extends between first and second securing members50 and 51. The first securing member 50 extends along and is attached toan inner edge of the first panel 16 and the second securing member 51extends along and is attached to an inner edge of the second panel 18.The hinge member 52 includes opposite edges that are captured in grooves50 a and 51 a defined in the first and second securing members 50 and51. In a preferred embodiment, the hinge member 52 is made of a materialthat provides hinging or pivot capability, and also allows it to bebiased toward the closed position (thereby making it easier for a userto close the door). For example, the hinge member 52 can be made of anelastomeric material or the like.

Preferably, the first and second securing members 50 and 51 each includea cavity or tunnel 54 extending therethrough. Furthermore, as describedbelow, an elongated bolt 56 that is operationally associated with thelatching assembly 22 extends through and is movable within the tunnel 54of the one or the other of the first and second securing members 50 and51.

In a preferred embodiment, the latching assembly 22 is positioned in thefirst panel and operates the elongated locking bolt 56. Preferably, thefirst securing member includes a latch opening 58 defined therein thatis in communication with the tunnel 54, and a portion of the latchingassembly 22 extends through the latch opening 58 and into the tunnel 54.In a preferred embodiment, the central hinge 20 includes a fixed hinge,pivot point or knuckle 66 at the top and bottom thereof. The fixed hinge66 can be part of the upper trim 38 and captures and secures the top ofthe living hinge (the same is at the bottom).

As shown in FIG. 2, in a preferred embodiment, the latching assembly 22interacts with the elongated bolt or locking mechanism 56. The singleaction bolt runs through the tunnel or cavity in the first securingmember of the central hinge extrusion and extends through an opening inthe upper trim 38. The top of the bolt moves between a released andlocking position. In the locking position, the bolt extends into areceptacle or the like in the header assembly 34, wall or structure,thereby preventing the door 15 from being opened. The drawings show alatching assembly or mechanism 22 that is operated by a user in ahorizontal manner, which in turn moves the bolt up and down. However, inanother embodiment, the latching assembly can be operated in a verticalmanner. In another embodiment, the latching mechanism can move a boltthat interacts horizontally with the vertical edge of the wall 14. Bybolting the panel or blade of the bi-fold door 15 to the header 34, andin conjunction with the interlocking leading edge, the door is securelylocked.

As shown in FIG. 5-6, in a preferred embodiment, the door 15 includesthe outer paddle handle 26 that is secured to and extends outwardly fromthe first panel 16 such that it overlaps at least a portion of the wall14. Preferably, the door 15 also includes the inner paddle handle 24that is secured to the second panel 18 and overlaps at least a portionof the first panel 16. In another embodiment, the inner paddle handle 24can be secured to the first panel 16 and overlap at least a portion ofthe second panel 16. The positioning of the handles makes it intuitivefor someone inside or outside the bathroom as to where and how to pullon the handle. As shown in FIG. 2, in a preferred embodiment, the wall14 includes a handle indentation 70 defined therein that includes aninsert 72 positioned therein. The outer paddle handle 26 overlaps andcooperates with the handle indentation 70 and the insert 72 to define anopening space 74. Preferably, the insert 72 includes a ramp portion 76leading into and partially defining the opening space 74.

As shown in FIGS. 7-8, in order to hingedly connect the trailing edge ofthe door 15 to the wall 14, the outer edge of the second panel 18includes the edge cap 32 secured thereto. The edge cap includes a tunnel78 extending therethrough and the upper hinge member 28 is positioned inthe tunnel 78 such that an upper hinge pin 80 extends above the edge cap32, and the lower hinge member 30 is positioned in the tunnel 78 suchthat a lower hinge pin 80 extends below the edge cap 32. The upper andlower hinge members 28 and 30 can be secured in the tunnel 78 by a screw82, adhesive, other threaded fasteners or any other securing method.

In a preferred embodiment, the upper and lower hinge members 28 bothinclude an L-slot 84 therein that includes a pin 86 that allows thespring biased hinge pin 80 to be moved axially. This allows the door tobe secured to the frame or allows the door to be removed in case of anemergency. Preferably, the L-slot 84 and pin 86 are accessible via awindow 88 defined in the edge cap 32.

FIGS. 10-18 show a door module 120 positioned within a door opening 12in a wall 14. In a preferred embodiment, the door module 120 is used inan aircraft lavatory. However, this is not a limitation on the presentinvention and the door module 120 can be used in other locations. Asshown in the drawings, in a preferred embodiment, the door module 120generally includes a bi-fold door 15 that includes a first panel 16 anda second panel 18 that are secured together and pivotable with respectto one another via a central hinge 20. Preferably, the central hinge 20is a living hinge (described below). However, this is not a limitationon the present invention and the center hinge can also be any other typeof known hinge. The door module 120 also includes a latching assembly122, an inner handle 24, an outer handle 26, upper and lower hingemembers 28 and 30, a doorframe edge cap 32, header assembly 34, lowercloseout 36, and upper and lower trim 128 and 130. The door module 120can include other components known in the art such as vents 100, kickplates 102, an ashtray 104, door damper 106, etc.

As shown in FIGS. 11-12, in a preferred embodiment, the upper portion ofthe bi-fold door 15 includes a roller bearing 132 extending upwardlyfrom the first panel 16 and the upper trim 128. The roller bearing 132moves, slides or rolls within a track in the header assembly 34 that issecured to the lower edge of the door opening 12 in the wall 14. Theroller bearing 132 is positioned such that when the bi-fold door 15moves between the open and closed positions, the leading edge of thedoor moves in a path shown in FIG. 14 and discussed further below.

As shown in FIGS. 13-14A, in a preferred embodiment, the leading edge ofthe bi-fold door 15 interlocks or nests within the door jamb when thebi-fold door 15 is in the closed position. To accomplish this, the firstpanel 16 includes a first nesting member 42 secured thereon thatinterlocks with a second nesting member 44 that is secured to the wall14. The first and second nesting members 42 and 44 can extend the entireheight of the door 15 or, as shown in the drawings, there can be upperand lower portions that extend above and below the outer handle 26. Thefirst and second nesting members 42 and 44 each include a channel 46into which the first panel 16 or wall 14 are received. In a preferredembodiment, the first and second nesting members 42 and 44 areextrusions and are secured to (via adhesive, screws, fasteners, etc.) tothe first panel 16 and wall 14. In another embodiment, the first nestingmember can be integral with the first panel and the second nestingmember can be integral with the wall.

It will be appreciated by those of ordinary skill in the art that theinterlocking feature of the first and second nesting members helpsprevent the door from being opened when the door (and, in particular,the first panel) is pushed from the inside (see arrow A1) in FIG. 14A.In a preferred embodiment, the first nesting member 42 includes anon-engagement portion or surface 42 a and an engagement portion orsurface 42 b. The non-engagement portion 42 a is generally parallel tothe outer edge of the first panel 16 (or generally perpendicular to thefront and back surfaces of the door). The engagement portion 42 b curvesor angles away from the non-engagement portion. The second nestingmember 44 also includes a non-engagement portion 44 a and an engagementportion 44 b. The non-engagement portion 44 a is generally parallel tothe inner edge of the wall 14 (or generally perpendicular to the frontand back surfaces of the wall), and is generally parallel to thenon-engagement portion 42 a of the first nesting member 42. Thenon-engagement portions can also be described as ramp portions. When aforce is placed on the door 15 in the direction of arrow A1, the firstpanel 16 moves outwardly and engagement portion 42 b contacts engagementportion 44 b, thereby preventing the door from opening. Generally, theoverlap between the first and second nesting members 42 and 44 in thelateral and/or transverse directions of the door 15 provides theinterlocking capability. In other words, the profile of the leading edgeof the door and the mating part on the wall or structure are shaped in afashion that they will securely retain the door from any inboardoutboard movement. They also eliminate any direct line of site throughthe gaps, preventing any unwanted light bleed and privacy issues.

It will be appreciated that the path traveled by the leading edge of thedoor, as a result of the interaction between roller bearing 132 and itstrack is what allows the first and second nesting members 42 and 44 tonest. This path is shown in FIG. 14 with reference to the variouspositions of the door shown in hidden lines and the path the rollerbearing 132 must travel within the track.

As shown in FIGS. 13 and 14B, in a preferred embodiment, the centralhinge 20 is or includes a living hinge that connects the first andsecond panels 16 and 18. In a preferred embodiment, the living hingeincludes a hinge member 52 that extends between first and secondsecuring members 50 and 51. The first securing member 50 extends alongand is attached to an inner edge of the first panel 16 and the secondsecuring member 51 extends along and is attached to an inner edge of thesecond panel 18. The hinge member 52 includes opposite edges that arecaptured in grooves 50 a and 51 a defined in the first and secondsecuring members 50 and 51. In a preferred embodiment, the hinge member52 is made of a material that provides hinging or pivot capability, andalso allows it to be biased toward the closed position (thereby makingit easier for a user to close the door). For example, the hinge member52 can be made of an elastomeric material or the like.

Preferably, the first and second securing members 50 and 51 each includea cavity or tunnel 54 extending therethrough. Furthermore, as describedbelow, an elongated bolt 56 that is operationally associated with thelatching assembly 122 extends through and is movable within the tunnel54 of the one or the other of the first and second securing members 50and 51.

In a preferred embodiment, the latching assembly 22 is positioned in thefirst panel and operates the elongated locking bolt 56. Preferably, thefirst securing member includes a latch opening 58 defined therein thatis in communication with the tunnel 54, and a portion of the latchingassembly 122 extends through the latch opening 58 and into the tunnel54. In a preferred embodiment, the central hinge 20 includes a fixedhinge, pivot point or knuckle 134 at the top and bottom thereof. Thefixed hinge can be part of the upper trim 38 and captures and securesthe top of the living hinge (the same is at the bottom). In a preferredembodiment, the fixed hinge 66 includes magnets 136 embedded arepositioned on opposite sides of the hinge (e.g. one on first panel 16and one on second panel 18) that are magnetically attracted to oneanother. This helps finish the closing of the door when it is moved tothe closed position.

As shown in FIG. 11, in a preferred embodiment, the latching assembly122 includes or interacts with an elongated bolt or locking mechanism56. The single action bolt runs through the tunnel or cavity in thefirst securing member of the central hinge extrusion and extends throughan opening in the upper trim 38. The top of the bolt moves between areleased and locking position. In the locking position, the bolt extendsinto a receptacle or the like in the header assembly 34, wall orstructure, thereby preventing the door 15 from being opened. Thedrawings show a latching assembly or mechanism 122 that is operated by auser by rotating a handle or other user interface member, which in turnmoves the bolt 56 up and down. The latching assembly 122 translatesrotational motion to linear/vertical motion. However, in anotherembodiment, the latching assembly can be operated in a vertical manner.In another embodiment, the latching mechanism can move a bolt thatinteracts horizontally with the vertical edge of the wall 14. By boltingthe panel or blade of the bi-fold door 15 to the header 34, and inconjunction with the interlocking leading edge, the door is securelylocked.

As shown in FIG. 14-15, in a preferred embodiment, the door 15 includesthe outer paddle handle 26 that is secured to and extends outwardly fromthe first panel 16 such that it overlaps at least a portion of the wall14. Preferably, the door 15 also includes the inner paddle handle 24that is secured to the second panel 18 and overlaps at least a portionof the first panel 16. In another embodiment, the inner paddle handle 24can be secured to the first panel 16 and overlap at least a portion ofthe second panel 16. The positioning of the handles makes it intuitivefor someone inside or outside the bathroom as to where and how to pullon the handle. As shown in FIG. 11, in a preferred embodiment, the wall14 includes a handle indentation 70 defined therein that includes aninsert 72 positioned therein. The outer paddle handle 26 overlaps andcooperates with the handle indentation 70 and the insert 72 to define anopening space 74. Preferably, the insert 72 includes a ramp portion 76leading into and partially defining the opening space 74.

As shown in FIGS. 16-17, in order to hingedly connect the trailing edgeof the door 15 to the wall 14, the outer edge of the second panel 18includes the edge cap 32 secured thereto. The edge cap includes a tunnel78 extending therethrough and the upper hinge member 28 is positioned inthe tunnel 78 such that an upper hinge pin 80 extends above the edge cap32, and the lower hinge member 30 is positioned in the tunnel 78 suchthat a lower hinge pin 80 extends below the edge cap 32. The upper andlower hinge members 28 and 30 can be secured in the tunnel 78 by a screw82 that is received in an opening 138 formed in the top of the edge cap32. The opening 138 can extend the length of the edge cap 32 and a screwcan be used to secure the lower hinge member 30 in place. As shown inFIGS. 14A and 14B, similar openings 138 can be included in the first andsecond securing members 50 and 51 and the first nesting member 42 forsecuring these components at the top and bottom thereof.

In a preferred embodiment, the upper and lower hinge members 28 and 30both include an L-slot 84 therein that includes a pin 86 that allows thespring biased hinge pin 80 to be moved axially. This allows the door tobe secured to the frame or allows the door to be removed in case of anemergency. Preferably, the L-slot 84 and pin 86 are accessible via awindow 88 defined in the edge cap 32.

Unless the context clearly requires otherwise, throughout thedescription and the claims, the words “comprise,” “comprising,” and thelike are to be construed in an inclusive sense, as opposed to anexclusive or exhaustive sense; that is to say, in the sense of“including, but not limited to.” As used herein, the terms “connected,”“coupled,” or any variant thereof, means any connection or coupling,either direct or indirect, between two or more elements; the coupling ofconnection between the elements can be physical, logical, or acombination thereof. Additionally, the words “herein,” “above,” “below,”and words of similar import, when used in this application, shall referto this application as a whole and not to any particular portions ofthis application. Where the context permits, words in the above DetailedDescription of the Preferred Embodiments using the singular or pluralnumber may also include the plural or singular number respectively. Theword “or” in reference to a list of two or more items, covers all of thefollowing interpretations of the word: any of the items in the list, allof the items in the list, and any combination of the items in the list.

The above-detailed description of embodiments of the disclosure is notintended to be exhaustive or to limit the teachings to the precise formdisclosed above. While specific embodiments of and examples for thedisclosure are described above for illustrative purposes, variousequivalent modifications are possible within the scope of thedisclosure, as those skilled in the relevant art will recognize.Further, any specific numbers noted herein are only examples:alternative implementations may employ differing values, measurements orranges.

The teachings of the disclosure provided herein can be applied to othersystems, not necessarily the system described above. The elements andacts of the various embodiments described above can be combined toprovide further embodiments. Any measurements described or used hereinare merely exemplary and not a limitation on the present invention.Other measurements can be used. Further, any specific materials notedherein are only examples: alternative implementations may employdiffering materials.

Any patents and applications and other references noted above, includingany that may be listed in accompanying filing papers, are incorporatedherein by reference in their entirety. Aspects of the disclosure can bemodified, if necessary, to employ the systems, functions, and conceptsof the various references described above to provide yet furtherembodiments of the disclosure.

These and other changes can be made to the disclosure in light of theabove Detailed Description of the Preferred Embodiments. While the abovedescription describes certain embodiments of the disclosure, anddescribes the best mode contemplated, no matter how detailed the aboveappears in text, the teachings can be practiced in many ways. Details ofthe system may vary considerably in its implementation details, whilestill being encompassed by the subject matter disclosed herein. As notedabove, particular terminology used when describing certain features oraspects of the disclosure should not be taken to imply that theterminology is being redefined herein to be restricted to any specificcharacteristics, features or aspects of the disclosure with which thatterminology is associated. In general, the terms used in the followingclaims should not be construed to limit the disclosures to the specificembodiments disclosed in the specification unless the above DetailedDescription of the Preferred Embodiments section explicitly defines suchterms. Accordingly, the actual scope of the disclosure encompasses notonly the disclosed embodiments, but also all equivalent ways ofpracticing or implementing the disclosure under the claims.

Accordingly, although exemplary embodiments of the invention have beenshown and described, it is to be understood that all the terms usedherein are descriptive rather than limiting, and that many changes,modifications, and substitutions may be made by one having ordinaryskill in the art without departing from the spirit and scope of theinvention.

What is claimed is:
 1. A door module for a vehicle lavatory, the doormodule comprising: a bi-fold door that includes a first panel and asecond panel each having an inner surface and an outer surface andpivotably connected together by a living hinge, wherein the living hingeincludes a hinge member that extends between first and second securingmembers, wherein the first securing member extends along and is attachedto an inner edge of the first panel and the second securing memberextends along and is attached to an inner edge of the second panel,wherein the bi-fold door is movable between a closed and an openposition, wherein the hinge member bends when the bi-fold door movesfrom the closed position to the open position, wherein the living hingeincludes a fixed hinge at a top thereof that secures the top of theliving hinge.
 2. The door module of claim 1 wherein an outer edge of thesecond panel includes an edge cap secured thereto, wherein the edge capincludes a tunnel extending therethrough, wherein an upper hinge memberis positioned in the tunnel such that an upper hinge pin extends abovethe edge cap, and wherein a lower hinge member is positioned in thetunnel such that a lower hinge pin extends below the edge cap.
 3. Thedoor module of claim 1 wherein the bi-fold door includes upper trim, andwherein the fixed hinge is a part of the upper trim.
 4. The door moduleof claim 3 wherein the living hinge includes first and second magnets onopposite sides thereof.
 5. A door module for a vehicle lavatory, thedoor module comprising: a bi-fold door that includes a first panel and asecond panel each having an inner surface and an outer surface andpivotably connected together by a living hinge, wherein the living hingeincludes a hinge member that extends between first and second securingmembers, wherein the first securing member extends along and is attachedto an inner edge of the first panel and the second securing memberextends along and is attached to an inner edge of the second panel, anda latching assembly positioned in the first panel, wherein the latchingassembly operates an elongated locking bolt, wherein the first securingmember includes a first tunnel defined therein, and wherein the lockingbolt extends through and above the first tunnel.
 6. The door module ofclaim 5, wherein the first securing member includes a latch openingdefined therein that is communication with the first tunnel, and whereina portion of the latching assembly extends through the latch opening andinto the first tunnel.
 7. A door module for a vehicle lavatory, the doormodule comprising: a bi-fold door that includes a first panel and asecond panel each having an inner surface and an outer surface andpivotably connected together by a central hinge, wherein the bi-folddoor is positioned in a door opening that is defined in a wall and ismoveable between a closed position and an open position, wherein anouter edge of the first panel includes a first nesting member thereon,wherein an inner edge of the wall adjacent the outer edge of the firstpanel includes a second nesting member thereon, and wherein at least aportion of the first and second nesting members overlap in a transversedirection when the bi-fold door is in the closed position, wherein thefirst nesting member includes an inner wall and an outer wall, andwherein the inner wall extends further from the first panel than theouter wall does.
 8. The door module of claim 7 wherein the first nestingmember includes a non-engagement portion and an engagement portion,wherein the second nesting member includes a non-engagement portion andan engagement portion, whereby when a force is placed on the innersurface of the first panel, the engagement portion of the first nestingmember contacts the engagement portion of the second nesting member toprevent the bi-fold door from opening.
 9. The door module of claim 7wherein the non-engagement portion of the first nesting member isgenerally parallel to the outer edge of the first panel, and wherein thenon-engagement portion of the second nesting member is generallyparallel to the inner edge of the wall.
 10. A door module for a vehiclelavatory, the door module comprising: a bi-fold door that includes afirst panel and a second panel each having an inner surface and an outersurface and pivotably connected together by a central hinge, wherein thebi-fold door is positioned in a door opening that is defined in a walland is moveable between a closed position and an open position, whereinan outer paddle handle is secured to and extends outwardly from thefirst panel such that it overlaps at least a portion of the wall,wherein the outer paddle handle has an inner surface that is incommunication with an exterior of the wall when the bi-fold door is in aclosed position such that a user can grasp the inner surface.
 11. Thedoor module of claim 10 wherein an inner paddle handle is secured to thesecond panel and overlaps at least a portion of the first panel.
 12. Thedoor module of claim 10 wherein the wall includes a handle indentationdefined therein, wherein the outer paddle handle overlaps and cooperateswith the handle indentation to define an opening space, wherein theopening space is defined between an outer surface of the handleindentation and the opposing inner surface of the outer paddle handle.13. The door module of claim 12 wherein an insert is positioned in thehandle indentation, and wherein the insert includes a ramp portionleading into and partially defining the opening space.
 14. A door modulefor a vehicle lavatory, the door module comprising: a wall that includesa door opening defined therein, a bi-fold door positioned in the dooropening and moveable between a closed position and an open position,wherein the bi-fold door includes a first panel and a second panel eachhaving an inner surface and an outer surface and pivotably connectedtogether by a living hinge, wherein the living hinge includes a hingemember that extends between first and second securing members, whereinthe first securing member extends along and is attached to an inner edgeof the first panel and the second securing member extends along and isattached to an inner edge of the second panel, wherein the hinge memberincludes opposite edges, wherein the first and second securing memberseach include an elongated groove defined therein, wherein the elongatedgrooves capture the opposite edges of the hinge member, wherein an outerpaddle handle is secured to and extends outwardly from the first panelsuch that it overlaps at least a portion of the wall, wherein the outerpaddle handle has an inner surface that is in communication with anexterior of the wall when the bi-fold door is in a closed position suchthat a user can grasp the inner surface, and wherein an inner paddlehandle is secured to the second panel and overlaps at least a portion ofthe first panel.
 15. The door module of claim 14 wherein the wallincludes a handle indentation defined therein, and wherein the outerpaddle handle overlaps and cooperates with the handle indentation todefine an opening space.
 16. The door module of claim 14 furthercomprising a latching assembly positioned in the first panel, whereinthe latching assembly operates an elongated locking bolt, wherein thefirst securing member includes a first tunnel defined therein, andwherein the locking bolt extends through and above the first tunnel. 17.The door module of claim 14 wherein an outer edge of the second panelincludes an edge cap secured thereto, wherein the edge cap includes atunnel extending therethrough, wherein an upper hinge member ispositioned in the tunnel such that an upper hinge pin extends above theedge cap, and wherein a lower hinge member is positioned in the tunnelsuch that a lower hinge pin extends below the edge cap.
 18. The doormodule of claim 14 wherein an outer edge of the first panel includes afirst nesting member thereon, wherein an inner edge of the wall adjacentthe outer edge of the first panel includes a second nesting memberthereon, and wherein at least a portion of the first and second nestingmembers overlap in a transverse direction when the bi-fold door is inthe closed position, wherein the first nesting member includes an innerwall and an outer wall, and wherein the inner wall extends further fromthe first panel than the outer wall does.
 19. The door module of claim18 wherein in the closed position the hinge member includes outwardlyfacing opposite edges, wherein the first and second securing memberseach include an inwardly facing elongated groove defined therein, andwherein the elongated grooves capture the opposite edges of the hingemember, and wherein the elongated grooves oppose one another.
 20. Thedoor module of claim 18 wherein the first nesting member includes anon-engagement portion and an engagement portion, wherein the secondnesting member includes a non-engagement portion and an engagementportion, whereby when a force is placed on the inner surface of thefirst panel, the engagement portion of the first nesting member contactsthe engagement portion of the second nesting member to prevent thebi-fold door from opening.
 21. The door module of claim 20 wherein thenon-engagement portion of the first nesting member is generally parallelto the outer edge of the first panel, and wherein the non-engagementportion of the second nesting member is generally parallel to the inneredge of the wall.